One step exterior flashing device

ABSTRACT

A flashing device comprising a flange comprising a front surface, back surface, and an opening wherein the opening is essentially centrally located in the flange and wherein the flange is suitable for attachment to a surface of an overlaid structural sheathing panel over a protrusion through the sheathing panel, and a gasket effective to essentially seal the perimeter of the protrusion to water, and an adhesive backing located on a back surface of the flange wherein the backing comprises an adhesive effective to permanently attach the flashing device to the surface of the overlaid structural sheathing panel. A system for flashing can comprise such a flashing device. A kit, building system or structure can comprise a flashing device as described and an overlaid wood composite panel.

BACKGROUND

Construction of buildings involves introduction of various apertures,e.g., for passage of various penetrants including utility/plumbingpipes. These apertures are potential sources of entry of atmospheric orenvironmental substances, especially water. Water has a natural tendencyto travel rearwardly on the exterior of a pipe for entry into thebuilding. If water enters through an exterior building wall, it cancause substantial damage.

In order to minimize the entry of substances, flashing may be installedduring construction. Flashing is the system used to seal edges at walls,expansion joints, and other places where the exterior envelope isinterrupted or terminated. Most effective flashing systems utilize theuse of gravity, sealing tapes, or a combination of both to drive awaywater from a wall. Flashing is often made of rubber, tar, asphalt,synthetic polymers, or various metals. Flashing devices used to preventmoisture from penetrating seams are well known in the industry.

Currently, flashing electrical boxes, vents, and openings is amulti-step process. Because of the nature of housewraps and felt paper,there is no standard way of flashing openings in wall or roof systems.Improper flashing practices result in water intrusion towards theinterior of a home, leading to water-/moisture-related problems.

One current product, for example, is the flashing system shown in FIG.1B. This product is installed over sheathing 120 in several steps: 1) Aflange 112 with rubber seal gasket 114 seals around the conduit 30 afterinstalling housewrap, felt, or building paper 140 beneath the lower halfof the penetration. 2) The flange 112 is pushed flush against the wall120. 3) The flange 112 is nailed 116 at the top corners; and 4)housewrap, felt, or building paper 140 is placed over the top half ofthe flange 112 to create a natural water drainage plane.

Another flashing system is shown in FIG. 1A. The steps for installingthis can include 1) installing a penetrant 30 in the sheathing 120; 2)applying flashing tape 214 around the penetrant 30; 3) placinghousewrap, felt or building paper 140 over the sheathing 120 but underthe flashing 214 which is around and under the lower half of thepenetrant 30; and 4) applying housewrap, felt or building paper 140 overthe top half of the penetrant 30. Another type of flashing is a“flap-type” system for non-standard openings such as a faucet.

These processes are inefficient and laborious. There exists a need for asimplified article, flashing system, and method for providing flashingfor openings in walls, roofs, and the like.

SUMMARY OF THE INVENTION

Described herein are articles and methods for flashing openings inwalls, roofs, and the like.

In one aspect, described herein is a flashing device. The device cancomprise a flange, a gasket, an opening, and an adhesive. The device cancomprise

(a) a flange comprising a front surface, back surface, and an opening,wherein the opening is essentially centrally located in the flange andwherein the flange is suitable for attachment to a surface of anoverlaid structural sheathing panel over a protrusion through thesheathing panel,(b) a gasket effective to essentially seal the perimeter of theprotrusion to water, and(c) an adhesive backing located on a back surface of the flange whereinthe backing comprises an adhesive effective to permanently attach theflashing device to the surface of the overlaid structural sheathingpanel. Optionally, the device can comprise an intermediate layer betweenthe flange and the adhesive backing.

In another aspect, described herein is a building system or kitcomprising an overlaid wood composite panel and a flashing device of theinvention. The system or kit can comprise (a) a flashing devicecomprising a flange comprising a front surface, back surface, and anopening, wherein the opening is essentially centrally located in theflange and wherein the flange is suitable for attachment to a surface ofan overlaid structural sheathing panel over a protrusion through thesheathing panel,

a gasket effective to essentially seal the perimeter of the protrusionto water, and an adhesive backing located on a back surface of theflange wherein the backing comprises an adhesive effective topermanently attach the flashing device to the surface of the overlaidstructural sheathing panel, and(b) an overlaid structural sheathing panel.

In a further aspect, described herein is a method of flashingpenetrations comprising adhesively attaching to an overlaid structuralsheathing panel

a flashing device comprising (i) a flange comprising a front surface,back surface, and an opening, wherein the opening is essentiallycentrally located in the flange andwherein the flange is suitable for attachment to a surface of anoverlaid structural sheathing panel over a protrusion through thesheathing panel, (ii) a gasket effective to essentially seal theperimeter of the protrusion to water, and (iii) an adhesive backinglocated on a back surface of the flange wherein the backing comprises anadhesive effective to permanently attach the flashing device to thesurface of the overlaid structural sheathing panel.

Additional advantages will be set forth in part in the description whichfollows, and in part will be obvious from the description, or may belearned by practice of the aspects described below. The advantagesdescribed below will be realized and attained by means of the elementsand combinations particularly pointed out in the appended claims. It isto be understood that both the foregoing general description and thefollowing detailed description are exemplary and explanatory only andare not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several aspects described below.Like numbers represent the same elements throughout the figures.

FIG. 1 shows several different types of installed flashing from avertical cross-sectional view of a wall. A=use of flashing tape;B=Quickflash (Quickflash Weatherproofing Products, Inc.®, Las Vegas,Nev.) flashing system; C=an embodiment of a flashing device of thecurrent invention.

FIG. 2 shows an embodiment of a flashing device of the currentinvention.

DETAILED DESCRIPTION

Before the present articles, devices, and/or methods are disclosed anddescribed, it is to be understood that the aspects described below arenot limited to specific example embodiments, specific embodiments may,of course, vary. It is also to be understood that the terminology usedherein is for the purpose of describing particular aspects only and isnot intended to be limiting.

In this specification and in the claims which follow, reference will bemade to a number of terms which shall be defined to have the followingmeanings:

It must be noted that, as used in the specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the context clearly dictates otherwise. Thus, for example,reference to “an adhesive” includes mixtures of adhesives; reference to“a polymeric material” includes mixtures of two or more such materials,and the like.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where the event or circumstance occurs and instances where itdoes not.

Ranges may be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

For purposes of this application, the term “overlaid” panel will refereither to panels used for walls, roofs, or other uses. Traditionally,“overlaid” refers to walls and “roof underlayment” generally applies toroofs; however, for ease of usage herein “an overlaid panel” is anypanel with an overlay attached, e.g., ZIP™ Wall or Roof Sheathing,whether used as wall or roof since structurally they are consideredsufficiently similar in the context of flashing.

A device is described herein which is used as flashing on openings inwalls, roofs, and the like. The device comprises a flange, a gasket, anopening, and an adhesive.

Also disclosed is a method of installing a flashing system on anaperture within structural sheathing by, e.g.,:

a. “locking and sealing” the diameter of a penetrant, such as a pipe,located within an aperture in structural sheathing with a rubber sealgasket,b. sealing a flange comprising the gasket against the structuralsheathing with a self-adhesive backing.

Use of a flashing device of the invention can eliminate the need forsteps of using a secondary tape or caulking to seal around apenetration/penetrant and/or fastening a flashing flange with mechanicaltype fasteners, e.g., nails or staples. Further, the device caneliminate layering of housewrap, etc. over and under a flashing device.

A device of the invention can complement, for example, the ZIP System™(wall and roof) product line (Huber Engineered Woods LLC, Charlotte,N.C.; www.huberwood.com; http://huberwood.com/)—the invention canprovide easier flashing installation compared with current traditionalfelt, building paper, or housewrap, essentially transforming amulti-step flashing process into a one-step flashing process.

A. Articles

A flashing device of the current invention allows for one step flashingwithout the need for additional securing means (e.g., nails, staples, orcaulk) and without the need to overlap/layer the flashing with buildingpaper or housewrap of any sort. However, either additional securingmeans or building paper/housewrap or both could also be used with thedevice, if desired.

In one aspect described herein are articles for flashing openings inwalls, roofs, and the like. A flashing device 10 of the invention cancomprise a flange 12, a gasket (e.g., rubber gasket) 14, and an adhesive(e.g., a self-adhesive) backing 16. See, e.g., FIG. 2 for an exampleembodiment. The device can be used, for example, in combination withstructural sheathing with built-in water-resistive barriers (or built-inroof underlayment) such as the ZIP™ Wall or Roof system, described in,e.g., in U.S. Pat. Nos. 6,737,155 and 6,772,569 and U.S. PublishedApplications 2005/0229504, 2005/0257469, and 2005/0229524, herebyincorporated by reference for their teachings on overlaid buildingpanels. The device can be used on other construction panels or materialsas well, e.g., coated panels, insulation board, panels withpost-manufacture applied coatings (e.g., spray or trowel-appliedwater-resistive barriers), etc.

Referring to FIG. 1C, an installed embodiment of a flashing device 10 isshown. FIG. 1C illustrates a device 10 in place on a pipe 30 installedon an overlaid panel wall 20. The device 10 has a gasket 14 with anopening 18 sized to permit passage of a pipe 30 therethrough andsufficiently small to snugly surround the pipe 30 such that anessentially water-tight seal at the interface of the pipe 30 and thegasket 14 is formed. A flange 12 surrounds the gasket 14, and preferablyis a plastic flange 12 with the gasket 14 centrally disposed therein, asshown. Such configuration can be achieved by differing processes such asinjection molding insert techniques or by adhesively securing the gasket14 to the flange 12 across a pre-formed opening 18 in the flange 12.

An adhesive backing 16 seals the device 10 to an overlaid wall panel 20,thereby making the device 10 an integral permanent component of the wall20. When water travels rearwardly on the exterior of the pipe 30 fromits opening, the water simply encounters the gasket 14 in sealingengagement with the exterior surface of the pipe 30. Because the watercan travel rearwardly no further, it simply flows downwardly bygravitational force over the flange 12 and to the ground.

Final finishing material such as siding, brick, stucco through which thepipe 30 projects is applied directly on and over the device 10, therebymaking the device 10 an integral component of the wall 20 for the lifeof the building structure.

Installation of a flashing device of the invention on a roof would bevery similar. Final finishing material for roof can include shingles,tile, metal, and the like.

A flange 12 of the device can comprise a material substantiallyimpervious to water, for example, a polymeric material (e.g., plastic,vinyl, etc.), metal (e.g., galvanized steel), or resinated paper. Thematerial is preferably flexible but with rigidity effective to retainits shape. The shape of the flange is not critical; any shape which iseffective for preventing atmospheric penetration of the opening can beused. For example, in FIG. 2, the flange is generally rectangular inshape, more particularly, square. One of ordinary skill in the art inthe art can determine an effective shape. The flange comprises a frontsurface 12 a and a back surface 12 b (not shown). The flange ispreferably made of a one-piece unitary sheet material and issubstantially planar in order to fit essentially flush to a wall, roof,or other surface in which the penetration is found. However, if thesurface to which the flange is to be attached is not planar, then theflange need not be planar. The size of the flange is one which iseffective for preventing atmospheric penetration of the opening. One ofordinary skill in the art in the art can determine an effective size.For example, one example embodiment has dimensions of 8″ W×8″ L×⅛″thick. The flange can be formed by methods known to one of ordinaryskill in the art such as by molding or extruding.

Within the flange 12 is an opening 18. The opening 18 is preferablyessentially centrally located within the flange 12. The size of theopening is effective to receive a protrusion therethrough, e.g., a pipe.One example embodiment of the device has a 3″ diameter circular opening.The opening is to be placed over a penetrant in a roof, wall, or thelike. The opening can, e.g., be essentially circular in shape, thoughthe shape is not critical. A variety of shapes and sizes of openings canbe provided in order to accommodate various protrusions.

A gasket 14 can comprise a polymer, e.g., a plastic film or a polymericelastomeric material, for example, rubber, nitrile, EPDM, polyurethane,polyurea, mixtures therof, copolymers thereof, and the like. Further,the gasket can comprise a solid or porous material, e.g., closed-cellfoam. The gasket is intended to fit snugly around the protrusion. Thegasket is oriented substantially in the same plane as the flange but isflexible and when installed will likely deform outside the flange plane.The gasket can be any element of the device which is effective forpreventing atmospheric penetration of the opening. One of ordinary skillin the art can determine an effective gasket. The gasket 14 can be anelastomeric material with an opening 18 sized to permit passage of apenetrant/protrusion (e.g., pipe 30) therethrough and sufficiently smallto snugly surround the penetration/protrusion such that an essentiallywater-tight seal at the interface of the penetration/protrusion and theelastomeric material is formed, for example, having a 2″ diametercircular opening. Rubber and plastic film having such elastomericproperties are two examples of usable elastomeric material.

The gasket 14 can be sized and shaped to be simply fitting within theopening 18 in the flange 12, e.g., as shown in FIG. 2, or can bedifferently sized and shaped. For example, the gasket can be formed inessentially the same size and shape as the flange but for the size ofthe opening therein. In an embodiment where the flange and gasket havesimilar sizes and shapes, the gasket would form an intermediate layerbetween the flange and the adhesive backing.

An adhesive backing 16 can, for example, be a pressure-sensitiveself-adhesive backing. The adhesive backing 16 serves to adhere theflashing device 10 to a wall 20, roof, or the like. The adhesive cancomprise any adhesive which is effective for preventing atmosphericpenetration of the opening and an effective adhesion between the flange12 and the wall 20. For example, in an example embodiment, the adhesivecan be acrylic, butyl, rubber, polyurethane or urethane, silicone,epoxy, latex, anaerobic, cyanoacrylate, asphaltic, oleoresinous,nitrile, or polysulfide. Examples of adhesives used in construction canbe found in Handbook of Adhesives and Sealants in Construction, Amstock,Joseph S., 2001, McGraw-Hill, New York. Choice of adhesives for use onan overlaid wood composite panel can be more flexible than many othersurfaces due to the character of an overlay, e.g., the overlay found onZIP™ sheathing. One of ordinary skill in the art can determine aneffective adhesive and an effective amount of adhesive to use. Theadhesive can be applied to the device using conventional methods, suchas spray coating or application with a roller.

The flashing device 10 can be assembled by, e.g., adhesively bonding thegasket to the flange or by injection molding insert techniques offorming the gasket within the flange. The flange, gasket, and adhesivebacking can be manufactured using conventional methods; one of skill inthe art can determine how to manufacture the components and combine themtogether.

The flashing can be adhesively attached to a surface, e.g., of a wall.It will be understood by one of ordinary skill in the art that thepresent flashing device can vary widely in many shapes and sizescommensurate with the dimensions of the conduit access hole and servicerequired, e.g., conduit, gas line, drainage line, duct work and thelike.

System

A system of the invention can comprise an overlaid wood composite panel.In particular, an example wood composite is oriented strand board, suchas described in U.S. Pat. Nos. 5,525,394 and 5,635,248, hereinincorporated by reference in their entireties. Embodiments of systems ofthe invention can comprise conventional wood composite panels as well asspecialty panels such as the ZIP System™ overlaid panels (described in,e.g., in U.S. Pat. Nos. 6,737,155 and 6,772,569 and U.S. PublishedApplications 2005/0229504, 2005/0257469, and 2005/0229524), coatedpanels, and the like.

A system of the invention preferably comprises a wood composite panelwith an integral water-resistive barrier/underlayment and a flashingdevice as described above.

The invention can include a kit comprising an overlaid wood compositepanel (such as those described in, e.g., in U.S. Pat. Nos. 6,737,155 and6,772,569 and U.S. Published Applications 2005/0229504, 2005/0257469,and 2005/0229524) and a flashing device of the invention as describedabove. The kit can comprise a plurality of flashing devices of varyingshapes, sizes, and opening sizes, for example.

B. Methods

The articles described above can be manufactured using known methods toone of ordinary skill in the art. For example, the device can be molded.In another example method, the flange and gasket can be stamped out of asheet material, including the center hole in each. The gasket can thenbe applied to the flange using an adhesive, e.g., manually using a handroller or automatically using automatic dispensing and applicationequipment. The self-adhesive backing can be applied by coating, such asby a hand roller or automatic application equipment. Optionally, theadhesive backing can be provided with a release film applied to theadhesive backing. If a release film is applied, it can be stamped out ofa sheet release liner material and then applied to the self-adhesivebacking. Another example method of manufacturing would be to layer theadhesive backing between release films in roll form using suitable means(e.g., roll-coating, curtain coating) then stamp out the layered releasefilm-backing in the same shape as the flange. In this method, onerelease film is removed from the adhesive backing to be applied to theflange, with pressure, leaving the second release film to be removedfrom the adhesive backing by an installer.

The invention includes a method for flashing an opening comprisinginstalling a device of the invention over an opening or penetration in astructural sheathing panel and sealing the device to the structuralsheathing panel. The gasket and opening of the device fits over anypenetrant through the opening or penetration. The method can furthercomprise providing an overlaid wood composite panel as the structuralsheathing panel, preferably a ZIP System™ panel as described above.

A method of installing a flashing system on apertures can comprise

a. placing a flashing device of the invention over a penetrant, suchthat the exterior (e.g., diameter) of the penetrant, such as a pipe, issealed with the gasket of the device, andb. sealing the device against the structural sheathing panel with aself-adhesive backing of the device.

Throughout this application, various publications are referenced. Thedisclosures of these publications in their entireties are herebyincorporated by reference into this application in order to more fullydescribe the compounds, compositions and methods described herein.

Various modifications and variations can be made to the compounds,compositions and methods described herein. Other aspects of thecompounds, compositions and methods described herein will be apparentfrom consideration of the specification and practice of the compounds,compositions and methods disclosed herein. It is intended that thespecification and examples be considered as exemplary.

1. A flashing device comprising (a) a flange comprising a front surface,back surface, and an opening wherein the opening is essentiallycentrally located in the flange and wherein the flange is suitable forattachment to a surface of an overlaid structural sheathing panel over aprotrusion through the sheathing panel, and (b) a gasket effective toessentially seal the perimeter of the protrusion to water, and (c) anadhesive backing located on a back surface of the flange wherein thebacking comprises an adhesive effective to permanently attach theflashing device to the surface of the overlaid structural sheathingpanel.
 2. The device of claim 1 wherein the flange comprises polymericmaterial, metal, or resinated paper.
 3. The device of claim 1 whereinthe flange is planar.
 4. The device of claim 1 wherein the gasketcomprises rubber, nitrile, EPDM, polyurethane, polyurea, mixturestherof, or copolymers thereof.
 5. The device of claim 1 wherein theadhesive comprises acrylic, butyl, rubber, polyurethane or urethane,silicone, epoxy, latex, anaerobic, cyanoacrylate, asphaltic,oleoresinous, nitrile, or polysulfide adhesive.
 6. The device of claim 1wherein the protrusion is a pipe.
 7. A system for flashing comprising(a) a flashing device comprising (i) a flange comprising a frontsurface, back surface, and an opening wherein the opening is essentiallycentrally located in the flange and wherein the flange is suitable forattachment to a surface of an overlaid structural sheathing panel over aprotrusion through the sheathing panel, and (ii) a gasket effective toessentially seal the perimeter of the protrusion to water, and (iii) anadhesive backing located on a back surface of the flange wherein thebacking comprises an adhesive effective to permanently attach theflashing device to the surface of the overlaid structural sheathingpanel and (b) an overlaid structural sheathing panel.
 8. The system ofclaim 7 wherein the flange comprises polymeric material, metal, orresinated paper.
 9. The system of claim 7 wherein the gasket comprisesrubber, nitrile, EPDM, polyurethane, polyurea, mixtures therof, orcopolymers thereof.
 10. The system of claim 7 wherein the wherein theadhesive comprises acrylic, butyl, rubber, polyurethane or urethane,silicone, epoxy, latex, anaerobic, cyanoacrylate, asphaltic,oleoresinous, nitrile, or polysulfide adhesive.
 11. The system of claim7 wherein the wherein the overlaid structural sheathing panel is aresin-impregnated paper overlaid wood composite structural sheathingpanel.
 12. A building kit comprising (a) a flashing device comprising(i) a flange comprising a front surface, back surface, and an openingwherein the opening is essentially centrally located in the flange andwherein the flange is suitable for attachment to a surface of anoverlaid structural sheathing panel over a protrusion through thesheathing panel, and (ii) a gasket effective to essentially seal theperimeter of the protrusion to water, and (iii) an adhesive backinglocated on a back surface of the flange wherein the backing comprises anadhesive effective to permanently attach the flashing device to thesurface of the overlaid structural sheathing panel and (b) an overlaidstructural sheathing panel.
 13. A structure having (a) at least oneexterior wall, the exterior wall comprising (i) an overlaid structuralsheathing panel, and (ii) an opening in the overlaid structuralsheathing panel, and (b) a flashing device adhesively attached to theexterior wall comprising (i) a flange comprising a front surface, backsurface, and an opening wherein the opening is essentially centrallylocated in the flange and wherein the flange is suitable for attachmentto a surface of the overlaid structural sheathing panel over aprotrusion through the sheathing panel, and (ii) a gasket effective toessentially seal the perimeter of the protrusion to water, and (iii) anadhesive backing located on a back surface of the flange wherein thebacking comprises an adhesive effective to permanently attach theflashing device to the surface of the overlaid structural sheathingpanel.
 14. The structure of claim 13 further comprising siding, brick orstucco installed externally to the external wall and the flashingdevice.
 15. The structure of claim 13 further comprising a protrusionthrough the opening in the panel.
 16. The structure of claim 15 whereinthe protrusion is a pipe.
 17. The structure of claim 13 furthercomprising (c) a roof comprising (i) a structural sheathing panel withintegral underlayment, and (ii) an opening in the integrally underlaidstructural sheathing panel, and (d) a flashing device adhesivelyattached to the roof comprising (i) a flange comprising a front surface,back surface, and an opening wherein the opening is essentiallycentrally located in the flange and wherein the flange is suitable forattachment to a surface of the integrally underlaid structural sheathingpanel over a protrusion through the sheathing panel, and (ii) a gasketeffective to essentially seal the perimeter of the protrusion to water,and (iii) an adhesive backing located on a back surface of the flangewherein the backing comprises an adhesive effective to permanentlyattach the flashing device to the surface of the integrally underlaidstructural sheathing panel.
 18. A method for flashing comprising (a)adhesively attaching a flashing device comprising (i) a flangecomprising a front surface, back surface, and an opening wherein theopening is essentially centrally located in the flange and wherein theflange is suitable for attachment to a surface of an overlaid structuralsheathing panel over a protrusion through the sheathing panel, and (ii)a gasket effective to essentially seal the perimeter of the protrusionto water, and (iii) an adhesive backing located on a back surface of theflange wherein the backing comprises an adhesive effective topermanently attach the flashing device to the surface of the overlaidstructural sheathing panel to an overlaid structural sheathing panel.19. The method of claim 18 wherein the overlaid structural sheathingpanel is a resin-impregnated paper overlaid wood composite structuralsheathing panel.
 20. The method of claim 18 further comprisinginstalling a protrusion through the overlaid structural sheathing panel.